Dual injection molding apparatus

ABSTRACT

A mold 300 for making a member having at least one first section of a first material and at least one second section of a second material includes first and second plates or mold halves 332,334 adapted to cooperate with each other when positioned in opposing relationship along a mold-closing axis and reciprocally movable relative to one another along the axis during a molding cycle. The first and second plates or mold halves 332,334 define a member-forming area therein when the mold is in a closed position. Sprues in the first and second plates or mold halves are in communication with the portions of the first and second sections respectively of the member-forming area. An ejector 348 for ejecting an eventually mold member includes one surface defining a boundary of the member-forming area. The ejector is movably disposed in one of the plates and is movable into the member-forming area. The ejector 348 is positionable in a first position such that the first material is introduceable through the at least one first sprue 356 while another surface of the ejector blocks the at least one second sprue. The ejector 348 is then positioned in a second position within the member-forming area such that the second sprue is uncovered. The second material is introduced into the second portion 212 of the member-forming area through the at least one second sprue.

RELATED APPLICATION INFORMATION

This application is a continuation of application Ser. No. 07/412,297filed Sept. 25, 1989, now abandoned, in turn, a division of applicationSer. No. 06/862,902 filed May 13, 1986, now U.S. Pat. No. 4,895,529 inturn a continuation-in-part of application Ser. No. 06/453,327 filedDec. 27, 1982 now abandoned.

FIELD OF THE INVENTION

This invention relates, generally, to an environmentally sealedconnector and more particularly to an electrical connector having aconnector housing which is comprised of a rigid section secured at oneor both ends thereof to a flexible section.

BACKGROUND OF THE INVENTION

In the electrical connector arts the use of rigid and flexible materialsfor use in the same connector is old in the art. Such uses, however,were generally in the form of washers, O-rings or physical matingthrough glues, force fits or threading of flexible to rigid material.The purpose in such a combination is generally to provide environmentalsealing or strain relief or to allow for replacement or insertion ofcontacts. U.S. Pat. No. 4,090,759 "Micro-Miniature Circular High VoltageConnector" issued May 23, 1978 to Hermann, Jr., and U.S. Pat. No.3,838,382 "Retention System For Electrical Contacts" issued Sept. 24,1974 to Sugar disclose such uses.

Since the use of rigid and flexible components for contact housings isgreat, it is desirable to have a contact housing in which the rigid andflexible material are integrally molded so as to become a unitary piece.One patent wherein relatively hard and relatively soft resilientmaterial are used together for insulator bodies is found in BritishPatent Specification No. 968,707 "Multi-Hardness Resilient ConnectorInsulator" published Sept. 2, 1964. The insulator bodies were designedto be used in a rigid connector shell.

It is an object of the present invention to produce a connector housingwherein one end is of a rigid material and not merely relativelyinflexible and the other end is of a flexible material thereby providingenvironmental sealing and restraining one end while providing aphysically secure base at the remaining end.

It is a further object to have a connector housing wherein the interfacebetween the two materials is relatively smooth and does not separatewhen pressure is exerted thereon.

It is another object of this invention to provide a connector housinghaving one section of rigid material secured at one end thereof to asection of flexible material which will accommodate and sealingly engagedifferent wire sizes without the need to exert external pressure by useof rigid connector shell or other means.

In addition it is an object of this invention to provide a connectorhousing having a second section of flexible material secured to theother end of the rigid material to provide a flexible resilient sealingmember for environmentally sealing the interface when the connectorhousing is mated with a complimentary housing member.

In addition it is an object of this invention to provide a mold formaking the connector housings and a cost effective method for makingsame.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to an environmentallysealed electrical connector characterized by a first housing memberhaving at least one passageway therethrough for receiving electricalterminal member, the housing having at least a first portion which is ofa rigid material and at least a second portion which is of a flexibleresilient material, the portions having a chemical affinity at theinterface point therebetween, at least one socket terminal disposed ineach terminal receiving passageway in the first housing and the socketterminating to an electrical conductor, a second housing having at leastone terminal receiving passageway extending therethrough, the housinghaving at least a first portion which is of a rigid material and atleast a second portion which is of a flexible material, the portionshaving a chemical affinity at the interface point therebetween, and atleast one pin terminal disposed in each terminal receiving passageway inthe second housing, the pin terminal terminating to an electricalconductor.

The present invention is further directed to an environmentally sealedconnector wherein at least one of the housing members has a flexibleresilient sealing member at both ends of the rigid portion, the secondflexible portion forming a means for environmentally sealing theinterface when the plug and receptacle are mated.

The invention is further directed to a method of and mold for making theabove connectors by dual injection molding.

Some of the objects and advantages of the invention having been stated,others will appear as the description proceeds, when taken in connectionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partly exploded view of the connector of the presentinvention;

FIG. 2 is a cross-sectional view taken through an assembled connector ofthe present invention;

FIG. 3 is a cross-sectional view of a mold showing the manufacturing ofthe present invention;

FIG. 4 is partly exploded view of an alternative embodiment of theconnector of the present invention;

FIG. 5 is a cross-sectional view taken through the unassembled connectorof FIG. 4;

FIG. 6 is a cross-sectional view taken through the assembled connectorof FIG. 4;

FIG. 7 is a partially exploded view of a further alternative embodimentof the present invention;

FIG. 7A is a fragmentary view of another alternative embodiment of thepresent invention.

FIG. 8 is a cross-sectional view of a mold used for manufacturing theconnector of FIG. 4 showing the mold in its open position;

FIG. 9 is a cross-sectional view of the mold of FIG. 8 in its closedposition; and

FIG. 10 is a cross-sectional view of the mold taken along line 10--10 ofFIG. 9.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows an exploded view of the connector of the present invention.The connector housing 10 has two portions, the housing flexible portion12 and the housing rigid portion 14. Housing mating seal 16 is disposedbetween the two connector housings 10. Seal 16 provides environmentalprotection upon mating of the two connector housing halves (shown moreclearly in FIG. 2). The housing mating seal 16 has a ridge 18 disposedat either end which additionally helps to rigidly hold the seal 16 ontothe housings 10. Connector housings 10 have contact passageways 20extending therethrough the passageways allowing insertion and/or removalof individual contacts. It is to be understood that the positioning andnumber of contact passageways 20 may vary without departing from thespirit and scope of the present invention. Also shown is a pin terminal22 and a socket terminal 24 each having a wire 26 attached thereto. FIG.1 further shows interface point 15 disposed on each of the connectorhousings 10 which demarcates the flexible and the rigid portions 12, 14.

A cross-sectional view of an assembled connector of the presentinvention is shown in FIG. 2. In this view it can be seen how thehousing mating seal 16 is fitted over the exterior of the housing rigidportions 14. Also shown are the wires 26 which pass through the contactpassageways 20 and are relatively rigidly held in place by a series ofannular protrusions 21 extending into terminal receiving passageway 20in the flexible portion 12. Protrusions 21 form an environmentally tightseal around the exterior of the wires 26 as well as providing strainrelief. In addition to providing strain relief and sealing, the flexibleprotrusions allow the same housing member to be used for a plurality ofsizes of wires while maintaining an environmental seal around the wires.Disposed in the interior of each passageway 20 are ledges 28 whichprovide for physical stops for the pin terminal 22 as well as the socketterminal 24. In this manner of construction the housings 10 are of ahermaphroditic nature, the pin or the socket terminals being usable inany of the housings 10.

The connector is assembled by inserting wires having terminals attachedthereto into the flexible portion 12 until the terminals are seatedagainst ledges 28 in rigid portion 14.

FIG. 3 shows a cross-sectional view of a molding portion of a machineutilized in the construction of the housing 10. The operation andgeneral characteristics of the mold are generally known by one skilledin the art and therefore only a brief description will be found below.The mold has a parting line 30 which denotes the "A" end plate or moldhalf 32 from the "B" plate or mold half 34. Also shown is the positionfor injection of the rigid material 36 as well as the flexible material38. Disposed on the mold is the upper pin 40 which has two upper corecontact passageway forming pins 42. The number of passageway formingpins 42 is dictated by the number of terminal passageways 20 and maytherefore vary accordingly. The lower core pin 44 has lower coreterminal passageway forming pins 46 and thereby in conjunction with theupper core terminal passageway forming pins 42 form terminal passageways20 through the housing 10. Further, the upper core passageway formingpins 42 have core pin indentations 43 disposed therein which are used toform annular protrusions 21 in the connector housing 10. An ejectorsleeve 48 is utilized to eject a finished connector housing 10 from themold as well as control the flow of the rigid and flexible materials 36,38 as described below. A hydraulic cylinder 50 is used to separate the"A" plate 32 from the "B" plate 34 and from each other as describedbelow.

The manufacturing of the component is accomplished by a closing of themold plates "A" and "B" 32, 34. The ejector means or ejector sleeve 48then moves upward to a point just slightly above the lower sprue 52thereby prohibiting the introduction of rigid material 36 therethroughwhile leaving the upper sprue 54 open. The soft or flexible material 38is then injected into the mold and forms the housing flexible portion12. The ejector sleeve 48 is then retracted to the position shown inFIG. 3 thereby defining the total overall length of the housing 10. Therigid material 36 is then injected through the sprue 52 which forms thehousing rigid portion 14. Since the housing flexible portion 12 remainsin the upper portion of the mold in the position shown, the gate at theend of sprue 54 is blocked thus preventing additional flexible material38 from entering into the mold before the introduction of the rigidmaterial 36. Owing to the temperature of the rigid material 36 inrelation to the flexible material 38, as well as the material utilized,it is believed a chemical affinity occurs between the two materials atthe interface point 15. After the materials are sufficiently cooled themold opens at the parting line 30 with the top core pins 42 movingoutwardly until the housing 10 is out of the cavity. The mold thencontinues to open pulling the housing 10 from the top core pins 42 suchthat housing 10 remains in the "B" plate 34. The ejector sleeve 48 isthen moved forward and ejects housing 10 from plate 34.

FIGS. 4, 5 and 6 disclose an alternative embodiment 100 of theenvironmentally sealed connector, having plug member 101 and receptaclemember 201. Plug and receptacle member 101, 201 are comprised of housingmembers 110, 210, each housing member 110, 210 having flexible portions112, 212 and rigid portions 114, 214 respectively. Housing members 110,210 further have at least one electrical terminal receiving passageway120, 220 extending therethrough, said passageways having flexibleportions 119, 219 and rigid portions 123, 223 respectively as best seenin FIGS. 5 and 6. Housing members 110, 210 in alternative embodiment 100are not hermaphroditic. The mating end of rigid passageway portion 123of plug member 101 is dimensioned to receive rigid portion 214 ofreceptacle member 201 when connector 100 is mated. Thus eliminatingsleeve member 18 shown in FIG. 1. Plug and receptacle members 101, 201further have polarizing means to ensure proper alignment and means forlocking the portions together. FIG. 4 also shows the use of optionalbores 229 which may extend partially into rigid portion 214. Similarbores may be used in rigid portion 114. These bores are used to reducethe amount of material used in molding the housing and to provideadditional surface area for purposes of cooling the molded material. Ascan be seen in FIGS. 5 and 6, rigid portion 114 of plug member 101 hasan annular ring 113 which extends partially over the interfacing surface115 between flexible portion 112 and rigid portion 114. The majority offlexible portion 112 extends rearwardly from the back of rigid portion114. Plug member 101 further has polarizing member 125 extending intopassageway 123, which cooperates with polarizing passageway 225 inreceptacle member 201 when the connector is mated. In addition, rigidportion 114 has at least one locking aperture 127 which cooperates withcorresponding locking protrusion 227 on receptacle member 201.

Plug portion 101 has a pin terminal member 22 disposed in respectiveterminal receiving passageways 120, said pin terminals 22 beingterminated to a conductor member 26. Terminal 22 is inserted intopassageway 120 through flexible portion 119 and into rigid portion 123until the collar on terminal rests against stop surface 128 inpassageway portion 123. Annular protrusions 121 in flexible passagewayportion 119 grip the wire to provide an environmental seal and strainrelief. Since protrusions 121 are flexible, the same size housing andpassageways can accommodate several wire sizes while maintaining theintegrity of the environmental seal.

The front portion of receptacle member 201 is further comprised ofannular interfacial sealing member 216 having an arcuate sealingsurface, formed of same flexible material as flexible portion 212. Inthis embodiment the arcuate sealing member is integrally molded onto therigid portion 214 and functions as an O-ring. When the plug andreceptacle members 101, 201 are mated, seal 216 is compressed withinconstricted portion 117 within plug passageway 123 and provides anenvironmental seal. Rigid portion 214 of receptacle 201 has an annularring 213 which extends partially over interfacing surfaces 215 betweenthe two materials.

Receptacle member 201 has a socket terminal 24 disposed in each terminalreceiving passageway 220, each socket terminal 24 being terminated to aconductor member 26. Socket terminals 24 are inserted into flexibleportion 219 of passageways 220 in the same manner as previouslydescribed. Passageway portions 219 have annular protrusions 221 whichfunction in the same manner as protrusions 121 in plug member 101.Socket terminal 24 is inserted within passageway 220 until its collarengages stop surface 228 as shown in FIGS. 5 and 6.

When plug and receptacle members 101, 201 are mated as shown in FIG. 6,pin terminals 22 are engaged in socket terminals 24, interfacial seal216 is in sealing engagement at 117 within plug member 101 and lockingprotrusion 227 on receptacle member 201 is engaged in locking aperture127 of plug member 101.

FIG. 7 shows a further alternative embodiment 400 of the connectorcomprised of plug 401 and receptacle 501. In this embodiment rigidportions 414, 514 of plug housing 410 and receptacle housing 510 extendrearwardly to essentially surround flexible portions 412, 512 (shown inphantom), except at rear surfaces 411, 511. Receptacle 501 includesinterfacial seal member 516 at a front end thereof.

FIG. 7A shows a further plug embodiment 601 wherein rigid portion 610has a plurality of annular interfacial sealing members 616 disposed atthe mating end thereof.

FIGS. 8, 9 and 10 illustrate the operation of mold 300 used to formreceptacle portion 201 of alternative embodiment 100 wherein flexiblematerial 338 is injected onto both ends of the rigid material 336. FIG.8 shows mold 300 in its open position, immediately prior to ejection ofreceptacle portion 201. FIG. 9 shows the formed receptacle portion 201in the closed mold. FIG. 10 is taken along line 10--10 in FIG. 9 andshows the runner system for injecting rigid and flexible materials 336,338. Mold 300 is comprised of plate means or mold halves including upperand lower plates or halves 332 and 334 which separate at parting line330. Upper plate or half 332 contains stationary upper core pin plate340 on which are mounted core pins 342 which form part of terminalreceiving passageway 220; core pin 341 which forms polarizing passageway225; and core pins (not shown) for forming bores 229 in rigid portion214. Lower plate or half 334 contains stationary lower core pin plate344 on which are mounted core pins 346 for forming the remaining part ofterminal receiving passageway 220; and ejector mechanism 348. The numberof core pins 346 in lower core pin plate 344 correspond to the number ofpins 342 on upper core pin plate 340. When the mold is closed,corresponding core pins 342 and 346 meet at 345 to form continuous pinsfor forming terminal receiving passageways 220.

Mold 300 is further comprised of two blocks 333, mounted on lower moldplate 334 which together form connector housing forming cavity 331.Blocks 333 have cavities 337 therein for receiving arms 335 which extendfrom upper mold plate to move blocks 333 into position as mold 300closes. Blocks 333 move outwardly in a horizontal direction as arms 335are withdrawn from blocks 333 when mold 300 is opened (indicated by thearrow) to release the external surface of the molded housing from themold.

FIG. 10 is a view taken at right angles to FIG. 9 and illustrates thesprue means, runner and gate system for forming housing 210. Rigidmaterial 336 is injected into cavity 331 through sprue 356 entering atgate 357. Flexible material 338 is injected into desired locations incavity 331 through sprue 358 entering at gates 360 and 362.

To mold connector housing 210 in accordance with the invention plate 334is moved into position against block 332, causing arms 335 to enterbores 337 to move blocks 333 into position to form cavity 331; pin 341to enter cavity 331 for forming polarizing passageway 225; and core pins342 to enter cavity 331 and engage respective core pins 346 in lowerplate 334.

Plate 368 is then lowered to insert block 370 into upper end of cavity331 and plate 372 is partially raised to insert end 339 of ejectorsleeve 348 into the opposite end of cavity 331, thus preserving theseportions of the cavity for subsequent injection of flexible material338. Rigid material 336 is injected into cavity 331 through sprue 356 toform rigid portion 214. Rigid material 336 is allowed to solidify on itssurface prior to removing block 370 and ejector sleeve end 339 toprovide space for molding the flexible portions at both the interfacialseal 216 and wire seal 212 areas. Molten flexible material 338 isinjected into the desired areas and is allowed to cool. Since the rigidportion 214 is not completely cooled before the second material isintroduced into the mold, there is some surface melting of the firstmaterial resulting in thermal intermingling of the two materials andconsequent molecular affinity at the interfacial areas.

After the housing 210 has cooled sufficiently to retain its shape, mold300 is opened along parting line 330. Plate 332 is moved away from plate334 thus removing core pins 342, 341 from the housing and arms 335 fromblock bores 337 accompanied by movement of blocks 333 to release theouter surfaces of housing member 210. Connector housing member 210 isejected from lower plate 334 by action of ejector means includingejector sleeve 348 and ejector plate 374 being moved against flexibleportion 212 and flange 213 by upward movement of plates 372 and 349respectively.

Thermosetting as well as thermoplastic materials may be used to makeconnector housings in accordance with this invention. Thermoplasticmaterials are preferred, however, because of reduced cycle time neededbetween successive moldings. With thermoset materials, the mold must bemaintained at a high temperature for a sufficient period of time toallow the material to cure. With thermoplastic materials, the mold needsto be cooled for a relatively short period of time to allow the materialto set. The type of materials used depend upon the specific applicationfor the connector. Generally thermosetting materials are used wheneverthe connectors will be used at elevated temperatures. The preferredtypes of materials are thermoplastics, thermoplastic elastomers andthermosetting rubbers. Fillers that may be added to the rigid materialsinclude conductive as well as nonconductive materials such as metallicparticles, conductive nonmetals, metalized nonconductive materials,glass fibers, etc.

To increase the chemical affinity between the two portions of theconnector, it is preferred that a similarly based polymer be used informing the rigid material 36, 336 and flexible material 38, 338. Thebasic polymer is modified to provide the desired characteristics.Preferably the rigid material is flame retardant filled material and theflexible material is unfilled and may contain antioxidants and otheradditives for controlling flow and release from the mold. In addition,materials having compatible but different polymer bases may be combined.

Where desired, antioxidants and other additives were added in accordancewith the following procedure: fluid additives were added via a fluidpump of known calibrated output. Dry additives were measured and mixedwith pellets of the base resin material. A twin screw extruder was usedto blend the material prior to entering the mold. Fluid additives areadded just prior to the time the dry ingredients left the materialhopper and entered the extruder.

The following examples illustrate the invention. They are not to beconstrued as limitations on the instant invention except as indicated inthe appended claims. All compositions are expressed as parts by weightexcept where specifically indicated otherwise.

EXAMPLE 1

An apparatus such as that shown in FIGS. 8-10 was used to produceconnector housings as follows. A quantity of POLYFLAM RPP1174, apolypropylene, containing about 0.1 percent IRGANOX 1010, anantioxidant, and 0.2 percent SEENOX 412S, an antioxidant, was injectedinto the mold cavity formed with the slides in the forward positions ata pressure of about 70 kg/cm sq. at about 193° C. The slides were thenretracted to expose the gates of the areas into which the SANTOPRENE201-64 a dynamic vulcanizate at about 196° C. was injected at a pressureof about 100 kg/cm sq. The mold was maintained at about 10° C. The totalcycle time was between 30 and 80 seconds.

POLYFLAM RPP1174 is a polypropylene available from A. Schulman Inc.,Akron, Ohio. IRGANOX 1010 is tetrakis-[methylene3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)proprionate]methane which isavailable from CIBA GEIGY, Inc. SEENOX 412S is pentaerythritoltetrakis(b-laurylthiopropionate), and is available from Argus ChemicalDivision, Witco Chemical Corp., Brooklyn, N.Y. SANTOPRENE 201-64 is adynamic vulcanizate comprising ethylene-propylene-diene monomer (EPDM)rubber particles with an average size of 0.001 mm dispersed in a matrixof polypropylene available from Monsanto Polymer Products Company.

EXAMPLE 2

Example 2 was the same as Example 1 except that the POLYFLAM RPP1174 didnot contain the antioxidants.

EXAMPLE 3

Example 3 was the same as Example 2 except that the SANTOPRENE 201-64included about 2.5 percent of 12,500 centistroke SILICONE FLUID,SWS-101. SILICONE FLUID, SWS-101 is a polydimethylsiloxane availablefrom SWS Silicones Corp., Edison, N.J.

EXAMPLE 4

Example 4 was the same as Example 3 except that Santoprene 101-64 wasused instead of Santoprene 201-64. The Santoprene 101-64 was injected atabout 196° C. at about 100 kg/cm sq.

EXAMPLE 5

Example 5 was carried out in a prototype mold for thermoset materialswhich was maintained at an average temperature of about 185° C. Thefirst material, a non-reinforced EPDM, was injected with a pressure ofabout 28 kg/cm sq. This material was allowed to cure for about 20seconds, then the second material, a 15 percent glass reinforced EPDM,was injected with a pressure of about 49 kg/cm sq. and allowed to curefor about 240 seconds. The completed item was then ejected from themold.

The following compositions were used for the non-reinforced andreinforced EPDMs.

NON-REINFORCED EPDM

    ______________________________________                                        Component      Amount - Parts by Weight                                       ______________________________________                                        Vistalon 3777.sup.1                                                                          175                                                            Zinc oxide     20                                                             Burgess Icecap K.sup.2                                                                       300                                                            Sunpar 2280.sup.3                                                                            35                                                             Di-Cup 4OKE.sup.4                                                                            9                                                              Silane A-172.sup.5                                                                           1.5                                                            Agerite MA.sup.6                                                                             1.5                                                            ______________________________________                                         .sup.1 Vistalon 3777 is a high molecular weight 75 percent oil extended       EPDM available from Exxon Chemical Americas, Houston, Texas.                  .sup.2 Burgess Icecap K is an anhydrous aluminum silicate available from      Burgess Pigment Co., Macon, Georgia.                                          .sup.3 Sunpar 2280 is a paraffinic oil available from Sun Oil Co.,            Philadelphia, Pennsylvania.                                                   .sup.4 DiCup 4OKE is dicumyl peroxide on Burgess KE Clay, 40 percent          active, available from Hercules Incorporated, Wilmington, Delaware.           .sup.5 Silane A172 is a vinyl silane available from Union Carbide Corp.,      Danbury, Connecticut.                                                         .sup.6 Agerite MA is a polymerized 1,2dihydro-2,2,4 trimethyl quinoline       available from R. K. Vanderbilt, Norwalk, Connecticut.                   

REINFORCED EPDM

    ______________________________________                                        Component      Amount - Parts by Weight                                       ______________________________________                                        Vistalon 6505.sup.7                                                                          40                                                             Vistalon 3708.sup.8                                                                          40                                                             LD 400.sup.9   20                                                             Zinc oxide     20                                                             Suprex Clay.sup.10                                                                           30                                                             Mistron Vapor Talc.sup.11                                                                    55                                                             Burgess Icecap K                                                                             45                                                             FEF Black.sup.12                                                                             20                                                             HAF Black.sup.13                                                                             20                                                             Sunpar 2280    35                                                             Stearic Acid   1                                                              Glass.sup.14 fibers                                                                          49                                                             Di-Cup 4OKE    9                                                              Silane A 172   1.5                                                            Agerite MA     1.5                                                            ______________________________________                                         .sup.7 Vistalon 6505 is a medium viscosity, fast curing EPDM available        from Exxon.                                                                   .sup.8 Vistalon 3708 is a high viscosity EPDM available from Exxon.           .sup.9 LD 400 is a low density pothelyene available from Exxon.               .sup.10 Suprex Clay is a hydrated aluminum silcate available from J. M.       Huber Corp., Macon, Georgia.                                                  .sup.11 Mistron Vapor Talc is magnesium silicate available from Cypress       Minerals Co., Los Angeles, California.                                        .sup.12 FEF Black is carbon black having particles with diameters in size     range of 30-40 × 10.sup.-6 mm available from Phillips Petroleum Co.     Bartlesville, Oklahoma.                                                       .sup.13 HAF Black is carbon black having particles with a diameter of         27-29 × 10.sup.-6 mm, available from Phillips Petroleum Co.             .sup.14 Available from Owens Corning Fiberglas Corp., Toledo, Ohio.      

The formulations were made using a Banbury Mixer technique as describedin U.S. Pat. No. 4,373,048, which is incorporated by reference herein.

The Banbury Mixer technique has one and two pass systems both of whichstart by introducing the polymer into the mixer to be softened by shearand heat. Then fillers and dry ingredients are added and mixed until ahomogeneous mixture is obtained. Thereafter, the liquid components areadded and mixed to achieve a homogeneous mixture. At this point for thetwo pass system, the mixture is removed and cooled, after which it isreintroduced to the mixer and at a lower temperature the catalyst orcuring agents are added in the second pass and the mixture can be storedand subsequently placed in mold to achieve the necessary curing andcross linking. In the one pass system, the catalysts or curing agentscan simply be added and the mix subjected to molding and allowed tocool.

Other materials which are believed to be useful in practicing thisinvention include, but are not limited to, other polypropylenes, glassreinforced polybutylene terephthalate, glass reinforced andun-reinforced nylon, and reinforced polyolefinic elastomers, for therigid materials; and copolyester thermoplastic elastomers, styreneterpolymers, and interpenetrating network polymers of olefinic-basedelastomers with silicon for flexible materials.

It is to be understood that many variations of the present invention maybe utilized without departing from the spirit and scope of the presentinvention. For example, differing shapes of connecting housings such asrectangular and/or oblong may be utilized as well as different sizes.Additionally, the contact apertures may vary in size and/or shape fromhousing to housing and with respect to each other. Also, a contact andhousing arrangement may be utilized in conjunction with bulkheadconnectors, circuit boards, and may therefore only require one connectorand housing as opposed to the pair shown in the drawings. Further, othertypes of contact arrangements may be utilized which may include the useof cables other than electrical cable such as, for example, fiberoptics, adaptor arrangements wherein socket or pin contacts are disposedat both ends of a connector or a combination thereof.

Therefore, in addition to the above enumerated advantages the disclosedinvention produces an environmentally sealable connector which issuitable for a multitude of uses and which is cost effective as well aseasy to manufacture.

In the drawings and specification, there has been set forth preferredembodiments of the invention, and although specific terms are employed,they are used in a generic and descriptive sense only, and not forpurposes of limitation.

We claim:
 1. A mold for making a member having at least one firstsection of a first material and at least one second section of a secondmaterial comprising:first and second plate means adapted to cooperatewith each other when positioned in opposing relationship along amold-closing axis, said first and second plate means being reciprocallymovable relative to one another along said axis during a molding cycle,said first and second plate means being engageable with each other anddefining a member-forming area therein when said mold is in a closedposition, said member-forming area having at least a portion of a firstsection in one of said plate means and at least a portion of a secondsection in the other of said plate means; at least one first and atleast one second sprue means in said first and second plate means incommunication with said portions of said first and second sectionsrespectively of said member-forming area, said sprue means being adaptedfor introducing said first and second materials respectively intodesired portions of said member-forming area; and ejector means forejecting an eventually molded part upon completion of a molding cycle,said ejector means being movable into said member-forming area duringejection of said molded part, said ejector means being adjacent saidmember-forming area and including one surface defining a boundaryportion of said member forming area; said ejector means beingpositionable in a first position with said one surface defining aboundary portion of said first section of said member-forming area intowhich said first material is introducible through said at least onefirst sprue means while another surface of said ejector means blockssaid at least one second sprue means, and said ejector means beingpositionable in a second position with said one surface defining aboundary portion of said second section of said member-forming area intowhich said second material is introducible through said at least onesecond sprue means after said another surface is moved to uncover saidat least one second sprue means, whereby said ejector means for ejectingthe eventually molded part also serves to effectively close off one ormore of the sprue means during a first stage of the molding process andalso defines an outer surface of the eventually molded part.
 2. The moldof claim 1 wherein said ejector means is a sleeve movably disposed inone of said plate means such that a part of said sleeve defines said onesurface of said ejector means.
 3. The mold of claim 1 further includingpassageway-forming core pins having a first portion disposed in one ofsaid plate means and a second portion extending into said member-formingarea and adapted to form passageways extending through said first andsecond sections of the member formed in the member-forming area.
 4. Themold of claim 3 wherein said core pins are aligned with saidmold-closing axis, and respective portions of said pins coextend fromsaid one surface of said ejector means to define respective continuouspassageway portions of said first and second sections of the eventuallymolded part.
 5. A mold for making a member having at least one firstsection of a first material and at least one second section of a secondmaterial comprising:first and second mold halves adapted to bereciprocally movable along a mold-closing axis to meet at an interfaceto define a member-forming area within said mold when said mold is in aclosed position, said member-forming area including at least one firstmolding portion for receiving said first material and at least onesecond molding portion for receiving said second material; at least onefirst and at least one second sprue means in said first and second moldhalves in communication with respective ones of said first and secondmolding portions in said member-forming area, said at least one firstand second sprue means being adapted for introducing said first andsecond materials respectively into desired portions of saidmember-forming area; and ejector means for ejecting an eventually moldedpart upon completion of a molding cycle, said ejector means beingmovable into said member-forming area during ejection of said moldedpart, said ejector means being adjacent said member-forming area andincluding one surface defining a boundary portion of said member-formingarea; said ejector means being positionable in a first position withsaid one surface defining a boundary portion of said first moldingportion of said member-forming area into which said first material isintroducible through said at least one first sprue means while anothersurface of said ejector means blocks said at least one second spruemeans, and said ejector means being positionable in a second positionwith said one surface defining a boundary portion of said second moldingportion of said member-forming area into which said second material isintroducible through said at least one second sprue means after saidanother surface is moved to uncover said at least one second spruemeans, whereby said ejector means for ejecting the eventually moldedpart also serves to effectively close off one or more of the sprue meansduring a first stage of the molding process and also defines an outersurface of the eventually molded part.
 6. The mold of claim 5 wherein atleast one of said first and second mold halves includes a furthermember-forming section and said mold further includes a cylindricalmember movably disposed in one of said mold halves, said cylindricalmember extending into at least a part of said first molding portion,said cylindrical member blocking access to said further member-formingsection during the insertion of said first material into said firstmolding portion, said cylindrical member being movable to unblock accessto said further member-forming section during insertion of said secondmaterial into said member-forming area whereby said second material mayalso be inserted into said further member-forming section.
 7. The moldof claim 5 further including passageway-forming core pins having a firstportion disposed in one of said first and second mold halves and asecond portion extending into said member-forming area and adapted toform passageways extending through said first and second sections of themember formed in the member-forming area.
 8. The mold of claim 7 whereinsaid core pins are aligned with said mold-closing axis, and respectiveportions of said pins coextend from said one surface of said ejectormeans to define respective continuous passageway portions of said firstand second sections of the eventually molded part.